CN113039067A - 复合泡沫制品 - Google Patents

复合泡沫制品 Download PDF

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Publication number
CN113039067A
CN113039067A CN201980075303.0A CN201980075303A CN113039067A CN 113039067 A CN113039067 A CN 113039067A CN 201980075303 A CN201980075303 A CN 201980075303A CN 113039067 A CN113039067 A CN 113039067A
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CN
China
Prior art keywords
foam article
skin
fibers
article
polyurethane foam
Prior art date
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Withdrawn
Application number
CN201980075303.0A
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English (en)
Inventor
D·伯格
K·L·董
D·尤尔曼
S·D·威勒尔
L-C·J·林
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Proprietect LP
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Proprietect LP
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Publication of CN113039067A publication Critical patent/CN113039067A/zh
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Abstract

本文公开了复合泡沫制品。复合泡沫制品包括聚氨酯泡沫芯，聚氨酯泡沫芯呈现第一表面和第二表面，第二表面与第一表面反向。第一表皮被设置在第一表面上而第二表皮被设置在第二表面上。聚氨酯泡沫芯的密度为15‑80kg/m3。第一和第二表皮包含多个纤维和聚合粘合剂。复合泡沫制品的每单位面积的重量为约500至约1,000g/m2，并且当根据SAE J949在约23℃下测试时，在压缩后厚度大于约2mm处，其强度大于17N。

Description

复合泡沫制品
技术领域
本公开总体上涉及复合泡沫制品。复合泡沫制品可用于汽车应用中。
背景技术
在运输行业中，致力于使驾驶员和乘客都感到舒适、安静、和在美学上令人愉悦的车辆内部。在汽车行业中，内部部件(如车顶内衬(headliner)、车顶内衬基板、遮阳板、后窗台、座椅、和车厢地板)用于结构、声学、和美学目的以为驾驶员和乘客提供舒适、安静、和在美学上令人愉悦驾驶体验。
需要具有改善性能的车顶内衬和其它部件。
发明内容
本公开提供复合泡沫制品。复合泡沫制品包括呈现第一表面和第二表面的聚氨酯泡沫芯，第二表面与第一表面反向。第一表皮被设置在第一表面上，而第二表皮被设置在第二表面上。第一和第二表皮包括多个纤维和聚合粘合剂。
在一些实施方式中，聚氨酯泡沫芯的密度为约45至约80kg/m3。在这些实施方式中，聚氨酯泡沫芯、第一表皮、和第二表皮的压缩前(pre-compression)厚度为约2至约5mm，并被压缩以形成复合泡沫制品，当根据SAE J949在约23℃下测试时复合泡沫制品在大于约2mm的压缩后(post-compression)厚度处具有大于约17N的强度。
在进一步实施方式中，复合泡沫制品包括分散在所述前述表皮的任一个和芯中和/或设置在在所述前述表皮的任一个和芯之间的包含乙烯和丙烯酸(EAA)共聚物的至少一个补充层。
附图说明
当结合附图考虑时，通过参考以下详细描述，随着本公开的优点变得更好理解，将容易地意识到本公开的优点。应当理解，附图仅是说明性的，并且不一定按比例绘制。
图1是包括包含本公开的复合泡沫制品的座椅和车顶内衬(headliner)的车辆内部的立体图。
图2是可用作汽车车顶内衬基板的本公开的复合泡沫制品的实施方式的展开横截面图。
图3是示例根据SAE J949测试的复合泡沫制品在约4mm的厚度处的强度的图表。
图4是示例根据SAE J949测试的复合泡沫制品在约4mm的厚度处的硬度的图表。
图5是示例根据SAE J949测试的复合泡沫制品在约2mm的厚度处的强度的图表。
图6是示例根据SAE J949测试的复合泡沫制品在约2mm的厚度处的硬度的图表。
图7是示例根据SAE J949测试的复合泡沫制品和各种比较泡沫制品在约4mm的厚度处的强度的图表。
图8是示例根据SAE J949测试的复合泡沫制品和各种比较泡沫制品在约4mm的厚度处的硬度的图表。
图9是示例根据SAE J949测试的复合泡沫制品和各种比较泡沫制品在约2mm的厚度处的强度的图表。
图10是示例根据SAE J949测试的复合泡沫制品和各种比较泡沫制品在约2mm的厚度处的硬度的图表。
图11是可用作汽车车顶内衬基板的本公开的复合泡沫制品的实施方式的另一展开横截面图。
图12是可用作汽车车顶内衬覆盖料(coverstock)的本公开的复合泡沫制品的实施方式的分解横截面图。
图13是实施例3-6的复合泡沫制品的分解立体图。
图14是实施例6和比较实施例8的吸声的图解分析。
图15是将实施例3、4、和5以及比较实施例5、6、和7的第一表皮(在基板的“A面”上)和聚氨酯泡沫芯之间的撕裂强度进行比较的图解分析。
图16是将实施例3、4、和5以及比较实施例5、6、和7的第二表皮(在基板的“C面”上)和聚氨酯泡沫芯之间的撕裂强度进行比较的图解分析。
图17是实施例3-6和比较实施例5-8的强度的图解分析。
图18是实施例3-6和比较实施例5-8的硬度的图解分析。
图19是实施例3和4与比较实施例5和6的垂度的图解分析。
图20是实施例4的包含EAA共聚物的附加层和聚氨酯泡沫芯的放大图像。
具体实施方式
复合泡沫制品在本文中公开，并且在整个附图中总体上以10示出。复合泡沫制品10包括呈现第一表面14和第二表面16的聚氨酯泡沫芯12，第二表面16与第一表面14反向。第一表皮18被设置在第一表面14上，而第二表皮20被设置在第二表面16上。复合泡沫制品10具体地适合于在内部汽车部件(如座椅、车顶内衬基板、车顶内衬、遮阳板、后窗台、和车厢地板)使用。现在参考图1，复合泡沫制品10可被用于在车辆内部2内的内部汽车部件中，例如，在机动车的车顶内衬6中或座椅4中。
然而，本公开的复合泡沫制品10不限于在汽车行业中使用。作为一个实例，复合泡沫制品10适合于在航天行业中使用，例如，在飞机中。作为另一实例，所述复合泡沫制品10适合于在家具行业中使用，例如，在床、沙发和椅子中。
如上所阐述，复合泡沫制品10包括聚氨酯泡沫芯12。聚氨酯泡沫芯12呈现第一表面14和第二表面16，第二表面16与第一表面14反向。
聚氨酯泡沫芯12包括在发泡剂存在下异氰酸酯和异氰酸酯-反应性组分(例如，含活性氢的化合物，如多元醇)的反应产物。聚氨酯泡沫芯12可以是选自聚氨酯、脲改性的聚氨酯、和碳二亚胺改性的聚氨酯的异氰酸酯基聚合物。当与聚氨酯结合使用时，术语“改性的”意指上至50％的聚合物键被取代。在一些实施方式中，聚氨酯泡沫芯12是半刚性聚氨酯泡沫。在各种优选实施方式中，聚氨酯泡沫芯12是半刚性聚氨酯泡沫。
在各种实施方式中，聚氨酯泡沫芯12是选自粘弹性泡沫、柔性泡沫、半刚性泡沫、和刚性泡沫中的至少一种的泡沫类型。例如，在一些实施方式中，例如，在复合泡沫制品10是坐垫、椅套、或车顶内衬覆盖料的情况下，聚氨酯泡沫芯12可包括柔性或粘弹性泡沫。在其它实施方式中，例如，在复合制品10是遮阳板(sun visor)、座椅靠背、后窗台、负载(load)或车顶内衬基板的情况下，聚氨酯泡沫芯12可包括半刚性或刚性泡沫。进一步，聚氨酯泡沫芯12可包括一个或多个泡沫的子层。子层可包括所阐述泡沫类型的各种组合。
聚氨酯泡沫芯12典型地是经由在发泡剂存在下异氰酸酯-反应性树脂组合物(包括多元醇)和异氰酸酯的放热反应而形成的。异氰酸酯-反应性树脂组合物、异氰酸酯、和发泡剂被统称为聚氨酯体系。适合的聚氨酯泡沫和聚氨酯体系商购自The Woodbridge Groupof Woodbridge,ON。
在一些实施方式中，包括车顶内衬实施方式，在制造设施中以泡沫“包(buns)”的形式生产块状聚氨酯泡沫用于聚氨酯泡沫芯12，泡沫“包”的尺寸为如4英尺(高度)×6英尺(宽度)×100英尺(长度)。然后将每个包切割成多个较短长度(例如，8英尺)的包，这取决于所生产的具体汽车车顶内衬的规格。然后将较短长度的包切削成适当厚度(例如，2至12mm)的片。
在一些实施方式中，包括车顶内衬实施方式，聚氨酯泡沫芯12的初始厚度为约2至约15、约2至约12、约2至约10、约2至约5、约3至约6、或约3至约10mm。在各种非限制性实施方式中，所有值与值的范围(包括上述值的值及上述值之间的值)在此明确考虑用于本文。
在很多实施方式中，聚氨酯泡沫芯12的初始(如果包括在压缩的内部部件中，则在压缩之前)密度为约24至约180、约40至约120、约22至约80、约45至约80、约50至约80、或约55至约75kg/m3。在各种非限制性实施方式中，所有值与值的范围(包括上述值的值及上述值之间的值)在此明确考虑用于本文。
尽管密度不是坚固性、硬度、或承重能力的量度，当此类性质可由压缩力挠度(Compression Force Deflection(“CFD”))表征。在一些实施方式中，在聚氨酯泡沫芯12是半刚性泡沫(例如，用于车顶内衬和车厢地板的半刚性聚氨酯泡沫)的情况下，当根据ASTMD3574-17-D测试时，聚氨酯泡沫芯12在10％挠度下的CFD为约10至约120、或约15至约100、或约30至约95、或约40至约90、或约50至约90、或约60至约90、或约70至约90PSI。在各种非限制性实施方式中，所有值与值的范围(包括上述值的值及上述值之间的值)在此明确考虑用于本文。
应当理解，本文所述层中的每个可多于一次被包括在复合泡沫制品10中。还应当理解，本文所述的不同类型的层中的每个可包括一个或多个子层，子层包括本文关于具体层所述的材料。进一步，本文所述的层可被包括在复合泡沫制品10内的不同位置中。当然，层可由膜、粉末、颗粒、和纤维的各种组合形成。如当阅读本公开并参考相应附图(例如，图2、11、12、和13)时将显而易见的，在本文描述和考虑了各种示例性、非限制性实施方式，示例性、非限制性实施方式示例了在复合泡沫制品10内的不同位置中的不同数量的层的用途。
如当阅读本公开并参考相应附图相应附图(例如，图2-5)时将显而易见的，数字后面的撇号通常指示第二个具体类型的层。例如，如图2中示例，复合泡沫制品10典型地包括一个或多个附加或补充聚合层24。由此，聚合层24可位于泡沫芯层12的一侧，并且第二和第三聚合粘合层24’、24”可位于聚氨酯泡沫芯12的另一侧。
现在参考图2，在一些实施方式中，复合泡沫制品10包括设置在第一表面14上的第一表皮18和设置在第二表面16上的第二表皮20。在大多数实施方式中，第一表皮18和/或第二表皮20为多孔材料层(如切碎的纤维玻璃、面纱(veil)、垫子(mat)等的层)的形式。尽管在附图中(例如，在图2中)未具体示例多孔层，应当理解，尽管第一表皮18和/或第二表皮20包括以多孔构型布置的多个部件，但它们表示为单层。也就是说，在附图中，第一表皮18和第二表皮20包括多个纤维和聚合粘合剂，其由两个子层表示，其中一个旨在表示多个纤维，而另一个旨在表示聚合粘合剂。应当理解，多个纤维和聚合粘合剂组合以形成每个表皮18、20。第一表皮18和第二表皮20可包括相似或不同的部件(例如，纤维、粘合剂等)，并且可以相似或不同量(例如，每单位面积不同重量，或不同厚度)包括在复合泡沫制品10中。
应当理解，图2、11、12、和13未按比例绘制，并且是用于说明目的。在这一点上，附加或补充聚合层24典型地将比第一表笔18或第二表皮20薄，但是该不同并未在图中如此描绘。
可将多个纤维可选地描述为多种纤维或一种纤维。多个纤维可以是织造的、非织造额、或任何其它适合的构造。多个纤维可以是天然存在的或合成的。多个纤维可包括所阐述的纤维类型的各种组合。
在各种实施方式中，多个纤维是选自以下的材料、包括选自以下的材料、包含选自以下的材料、基本上由选自以下的材料组成、或由选自以下的材料组成：聚合物、陶瓷、玻璃、金属、矿物、和碳。在各种实施方式中，纤维是以下的纤维、包括以下的纤维、包含以下的纤维、基本上由以下的纤维组成、或由以下的纤维组成：芳族聚酰胺纤维、碳纤维、纤维素纤维(包括南非槿麻和大麻)、丙烯酸纤维、聚乙烯醇纤维、玻璃纤维、矿物纤维、金属纤维、和其组合。
在一些实施方式中，多个纤维包括聚合物。也就是说，多个纤维包括聚合物，基本上由聚合物组成，或由聚合物组成。
例如，在一些这样的实施方式中，多个纤维包括芳族聚酰胺(aramid或aromaticpolyamide)。在很多实施方式中，纤维包括聚芳酰胺(即，芳族聚酰胺)，包含聚芳酰胺(即，芳族聚酰胺)，基本上由聚芳酰胺(即，芳族聚酰胺)组成，或由聚芳酰胺(即，芳族聚酰胺)组成。芳族聚酰胺纤维是一类耐热的和坚固的合成纤维。在一些实施方式中，聚芳酰胺是间位芳族聚酰胺纤维。在其它实施方式中，聚芳酰胺是对位芳族聚酰胺。芳族聚酰胺纤维可以是各种长度和直径的纸浆或绒屑。
芳族聚酰胺典型地是通过胺和羧酸卤化物反应形成的。在一个实施方式中，芳族聚酰胺进一步被限定为具有至少约85％的直接附接于两个芳环的酰胺键(-CO-NH-)。在一些实施方式中，添加剂可与芳族聚酰胺一起使用，并且已经发现，按重量计上至多达10％的其它聚合材料可与芳族聚酰胺掺合，或者可以使用具有多达10％的其它二胺取代的芳族聚酰胺的二胺或多达10％的其它二酰氯取代的芳族聚酰胺的二酰氯的共聚物。为此目的，本文所考虑和公开的芳族聚酰胺纤维还包括芳族聚酰胺共聚物，例如，包括酰胺和其它键的聚合物。在一些实施方式中，聚芳酰胺选自聚对苯二甲酰对苯二胺、聚间苯二甲酰间苯二胺、聚醚-聚脲共聚物(弹性纤维(elastane))、和其混合物。
在一些实施方式中，多个纤维包括聚酯。例如，对苯二甲酸基聚酯。对苯二甲酸基聚酯的非限制性实例包括聚对苯二甲酸乙二酯(PET)、聚对苯二甲酸丁二酯(PBT)、聚对苯二甲酸丙二酯(PTT)、和聚萘二甲酸乙二酯(PEN)。在其它实施方式中，多个纤维包括选自聚对苯二甲酰对苯二胺、聚间苯二甲酰间苯二胺、聚醚-聚脲共聚物(弹性纤维)、和其混合物的聚芳酯。
在其它实施方式中，多个纤维包括矿物或玻璃。也就是说，多个纤维包括玻璃，基本上由玻璃组成，或由玻璃组成。在这样的实施方式中，多个纤维可包括选自E-玻璃(氧化铝-钙-硼硅酸盐)、S2玻璃(镁-铝-硅酸盐)、C玻璃(硼硅酸钙)、和R玻璃中的至少一种的玻璃类型。在一些实施方式中，多个纤维可包括选自二氧化硅、玄武岩、和石英中的至少一种的矿物类型。
在此在各种非限制性实施方式中明确考虑前述纤维类型的各种组合的所有重量范围和比率。
在包括第一表皮18和第二表皮20的典型实施方式中，表皮18、20中的每个包括单个多孔层。可选地，表皮18、20中的每个可包括多个多孔层。在这样的实施方式中，可以使用2至15个多孔层、2至12个多孔层、2至10个多孔层、2至8个多孔层、或4至8个多孔层。
第一表皮18和第二表皮20还包括聚合粘合剂。在各种实施方式中，粘合剂包括聚合物，包含聚合物，基本上由聚合物组成，或由聚合物组成。聚合粘合剂可包括所阐述聚合物类型的各种组合。聚合物的一些非限制性实例包括环氧树脂、聚氨酯、聚脲、酚醛塑料、聚丙烯酸酯、硅酮、聚硫化物、聚烯烃、聚酯、尼龙、聚氯乙烯、乳胶、苯乙烯-丁二烯聚合物、腈基-丁二烯聚合物、其混合物，其共聚物和其互穿网络。在一些实施方式中，聚合粘合剂包括选自聚乙烯和聚丙烯的聚合物。
如上所暗示，复合泡沫制品10可包括一个或多个不同于聚合粘合剂的附加或补充聚合层24。如果包括的话，附加或补充聚合层24可作为粉末、粗布(scrim)、或膜包括在复合材料中，或由粉末、粗布(scrim)、或膜形成。可将此类层设置在聚氨酯泡沫芯12的第一表面14和/或第二表面16上以改善聚氨酯泡沫芯12的表皮18、20的附着力。可选地，在一些实施方式中，附加或补充层24可被并入表皮18、20中和/或被设置在表皮18、20上。
当然，一个或多个附加聚合层24包括聚合物。在一些实施方式中，聚合物是热塑性塑料。在其它实施方式中，聚合物是热塑性弹性体。在其它实施方式中，聚合物是弹性体。在一些实施方式中，聚合物是热固性树脂，其包括环氧树脂、聚氨酯、聚脲、酚醛塑料、丙烯酸酯、丙烯酸酯、硅酮、聚硫化物、聚酯、和其混合物。可使用的聚合物的各种非限制性实例包括聚烯烃、聚酯、尼龙、聚氯乙烯、聚氨酯、聚丙烯酸酯、乳胶、苯乙烯-丁二烯聚合物、腈基-丁二烯聚合物、硅酮聚合物、聚异丁烯、其混合物、其共聚物和其互穿网络。
在一些优选实施方式中，一个或多个附加聚合层24包括聚烯烃。
在一些优选实施方式中，一个或多个附加聚合层24包括聚乙烯、聚对苯二甲酸乙二酯、乙烯和丙烯酸共聚物(“EAA共聚物”)、聚乙烯、聚丙烯、和其组合。
在一些这样的实施方式中，至少一个附加层24(例如，包含EAA共聚物)以以下量利用：约8至约30、约10至约20、或约10至约15(例如，13)g/m2。在各种非限制性实施方式中，所有值与值的范围(包括上述值的值及上述值之间的值)在此明确考虑用于本文。
进一步，在一些实施方式中，至少一个附加层24(例如，包含EAA共聚物)作为膜利用，当根据ASTM D882测试时，膜的拉伸伸长率为约200至约400％MD和约350至约550％TD。在各种非限制性实施方式中，所有值与值的范围(包括上述值的值及上述值之间的值)在此明确考虑用于本文。
在一些实施方式中，附加聚合层(一个或多个)24包含EAA共聚物，并且由设置在聚氨酯泡沫芯12的第一表面14和/或第二表面16上的膜或粉末形成以改善表皮18、20对聚氨酯泡沫芯12的附着力。可选地，附加或补充层24可被并入到表皮18、20中和/或设置在表皮18、20上。当利用EAA共聚物时，其对聚氨酯泡沫芯12提供出色的附着力。下面详细描述的图11和12是复合泡沫制品110、210的各个层的分解视图，其利用包含EAA共聚物的补充层(一个或多个)124、124’、224。
在一些实施方式中，包含EAA共聚物的附加或补充层24由单层的EAA共聚物膜形成。在其它实施方式中，包含EAA共聚物的附加或补充层24由多层的EAA共聚物膜形成。这样的膜实施方式的补充层24可相同或不同。在一些实例中，膜利用多层的EAA共聚物膜。在其它实例中，膜包括包含第一聚合物(例如，EAA共聚物)的一个或多个层和包含第二聚合物(例如，聚乙烯)的一个或多个层。
例如，在一些实施方式中，附加或补充层(一个或多个)24包含EAA共聚物，并且由包含不同聚合物类型的多个子层形成。在一些具体实例中，补充层24包括包含EAA共聚物的第一子层、包含聚乙烯或聚丙烯的第二子层、和包含聚乙烯或聚丙烯的第三子层(例如，以其中第二子层被设置在第一和第三子层之间的构型)。在很多优选实施方式中，包含EAA共聚物的第一子层被电晕处理。
也就是说，附加或补充层(一个或多个)24的表面可被电晕处理。当附加或补充层(一个或多个)24被用于促进复合泡沫制品10的各个层对聚氨酯泡沫芯12的表面的附着力时。电晕处理的表面具有附加或补充层(一个或多个)24，附加或补充层(一个或多个)24邻接聚氨酯泡沫芯12的第一表面14或第二表面16。例如，在一些实施方式中，在利用补充层24以改善复合泡沫制品10的各个层对聚氨酯泡沫芯12的附着力的情况下，补充层24包括电晕处理的包含EAA共聚物的第一子层、包含聚乙烯或聚丙烯的第二子层、和包含聚乙烯或聚丙烯的第三子层，并且形成(例如，层压)复合泡沫制品10，其中电晕处理的包含EAA共聚物的第一子层面向聚氨酯泡沫芯12。在一个具体实施方式中，补充层24包括电晕处理的包含EAA共聚物的第一子层、包含聚乙烯的第二子层、和包含聚乙烯的第三子层。
在一些非限制性实例中，包括包含EAA共聚物的第一子层、包含聚乙烯或聚丙烯的第二子层、和包含聚乙烯或聚丙烯的第三子层的补充层24被利用于车顶内衬基板、车顶内衬罩(headliner cover)、椅套等中。在这样的实施方式中，包括包含EAA共聚物的第一子层、包含聚乙烯或聚丙烯的第二子层、和包含聚乙烯或聚丙烯的第三子层的补充层(一个或多个)24典型地被设置在聚氨酯泡沫芯12的第一表面14和/或第二表面16上，其中EAA共聚物面向聚氨酯泡沫芯12的第一表面14和/或第二表面16。
在其它此类实施方式中，至少一个附加层24(例如，包含EAA共聚物)被作为膜利用，膜的厚度为约5至约50、约10至约30、约12至约25、或约13至约25(例如，约15、16、17、18、或19)μm。在各种非限制性实施方式中，所有值与值的范围(包括上述值的值及上述值之间的值)在此明确考虑用于本文。
在一些实施方式中，在附加层(一个或多个)24包括多个子层的情况下，利用较厚的第二子层(例如，其厚度为第一子层的厚度的至少两倍，并且，如果包括的话，为第三子层的厚度的至少两倍)。作为非限制性实例，附加层(一个或多个)24可包括厚度为约2至约4.5μm的第一子层(例如，包含EAA共聚物)、厚度为约8至约14μm的第二(或中心)子层、和厚度为约2至约4.5μm的第三子层。作为另一非限制性实例，附加层(一个或多个)24可包括厚度为约2至约4μm的第一子层(例如，包含EAA共聚物)、厚度为约8至约14μm的第二子层。
进一步，在一些实施方式中，至少一个附加层24(例如，包含EAA共聚物)被作为膜利用，当根据ASTM D1922测试时，膜的Elmdorf抗撕裂强度为约15至约35g MD和约200至约540g TD。在各种非限制性实施方式中，所有值与值的范围(包括上述值的值及上述值之间的值)在此明确考虑用于本文。
复合泡沫制品10可任选地包括一个或多个捕获层(catch layer)。一个或多个捕获层“捕获”VOCs，即，并减少复合泡沫制品10的VOC排放和吸收从乘坐室内的VOCs以改善乘坐室中的空气质量。一个或多个捕获层可分散在任一前述层中和/或设置在任一前述层之间。
捕获层包括碳颗粒，碳颗粒的表面积为大于约300m2/g。这种高表面积碳通常被称为活性炭(activated carbon，active carbon)、或活性的木炭。碳颗粒具有小、低体积孔，这增加可用于吸附和/或化学反应的表面积。
由于其高度的微孔率，一克的活性炭可具有超过3,000m2/ft的表面积。典型地，碳颗粒的表面积通过空气吸附来确定。碳颗粒以高表面积为函数吸收VOCs。然而，在一些实施方式中，碳颗粒可被化学处理以进一步增强其吸附性质。在一些实施方式中，碳颗粒的表面积为大于约300、大于约600、大于约900、大于约1,200、大于约1,500、大于约1,800、大于约2,100、大于约2,400、大于约2,700、或大于约3,000m2/g。可选地，在一些实施方式中，碳颗粒的表面积为约500至约5,000、约600至约4,500、约600至约3,500、或约700至约2,500m2/g。在各种非限制性实施方式中，所有值与值的范围(包括上述值的值及上述值之间的值)在此明确考虑用于本文。
如果包括的话，碳颗粒典型地以颗粒或粉末的形式(而不是以片形式或一些其它形式)包括在复合泡沫制品10中。在一些实施方式中，碳颗粒的平均粒度为约5至约1,000、约5至约100、约5至约60、约5至约35、约8至约32、或约10至约60μm。平均粒度是作为尺寸计算的以μm表示的平均粒径，其中50％(按重量计)的粒料较小。在各种非限制性实施方式中，所有值与值的范围(包括上述值的值及上述值之间的值)在此明确考虑用于本文。
在一些实施方式中，碳颗粒由选自椰子壳、石炭、和木材中的至少一种的原料制成。在一个具体实施方式中，碳颗粒由椰子壳制成。各种类型的碳颗粒商购自：Columbus,OH的Jacobi Carbons,Inc.，商标名为ADDSORBTM；Excelsior Springs,MO的Liberty CarbonService Inc.；或Pittsburgh,PA的Calgon Carbon Corporation。
除了碳颗粒之外，捕获层可包括各种其它吸收剂、抗氧化剂、填料、和其它添加剂。例如，在一些实施方式中，捕获层进一步包括沸石。沸石是微孔硅铝酸盐矿物。在一个具体实施方式中，捕获层包括碳颗粒和沸石。
在一些实施方式中，捕获层包含的碳的量为约2至约200、约2至约50、约5至约50、或约10至约40g/m2。在各种非限制性实施方式中，所有值与值的范围(包括上述值的值及上述值之间的值)在此明确考虑用于本文。
应当理解，复合泡沫制品10可包括各种构型的附加层。例如，复合泡沫制品10典型地包括面向乘坐室的成品外层(finished outer layer)，成品外层邻近第一表皮18设置。
除了用作车顶内衬基板之外，上述复合泡沫制品10的实例可用作具有相同或不同层组合的座椅靠背、后窗台、和车厢地板。
在很多实施方式中，复合泡沫制品10的压缩前厚度为约2至约5mm，而压缩后厚度为大于约1.5mm、大于约2mm、约1.5至约5、或约2至约4.5mm。下面关于形成(例如，层压)复合泡沫制品10的方法进一步描述压缩前和压缩后厚度。
在很多实施方式中，复合泡沫制品10是多孔的，并且其孔隙率提供增强的声学性质，而其结构提供增强的强度。在各种实施方式中，当根据ASTM C522-03测试时，复合泡沫制品10的气体流动阻力(air flow resistance)为大于约250、大于约500、大于约750、约500至约7,500、或约500至约5,000mks rayls(Pas/m)。ASTM C522-03涵盖多孔材料的气体流动阻力的测量和具体气体流动阻力和气体流动抵抗性(air flow resistivity)的相关测量，多孔材料可用于声音的吸收和衰减。ASTM C522-03被设计用于测量范围从100至10,000mks rayls(Pas/m)的具体气体流动阻力的值。
在很多实施方式中，复合泡沫制品10的每单位面积的重量为约500至约1,200、约750至约1,200、约750至约1,000、约800至约1,200、约800至约1,000、约700至约1,000g/m2。第一表皮18和第二表皮20累积贡献了复合泡沫制品10的每单位面积的总重量的约25至约60、或约30至约55％。在各种非限制性实施方式中，所有值与值的范围(包括上述值的值及上述值之间的值)在此明确考虑用于本文。
在很多实施方式中，当根据SAE J949在室温(约23℃)下和/或在高温(约80℃)下测试时，在约4mm的压缩后厚度处，复合泡沫制品10的压缩后硬度为大于约8、大于约9、大于约10、大于约12、大于约14、约10至约25、约12至约25、或约14至约25N/mm。在各种非限制性实施方式中，所有值与值的范围(包括上述值的值及上述值之间的值)在此明确考虑用于本文。
在一些实施方式中，当根据SAE J949在室温(约23℃)下和/或在高温(约80℃)下测试时，在约2mm的压缩后厚度处，复合泡沫制品10的压缩后硬度为大于约3N/mm、大于约3.5N/mm、或约3N/mm至约12N/mm。在各种非限制性实施方式中，所有值与值的范围(包括上述值的值及上述值之间的值)在此明确考虑用于本文。
在很多实施方式中，当根据SAE J949在室温(约23℃)下和/或在高温(约80℃)下测试时，在压缩后厚度为大于约2、约2至约5、约2至约4、约2mm、约4mm处，复合泡沫制品10的强度为大于约10、大于约11、大于约12、大于约13、大于约14、大于约15、大于约16、大于约17、大于约18、大于约19、大于约20、大于约21、大于约22、大于约25、大于约30、大于约35、大于约40、大于约45、或大于约50N。在各种非限制性实施方式中，所有值与值的范围(包括上述值的值及上述值之间的值)在此明确考虑用于本文。
还公开了形成(例如，层压)复合泡沫制品10的一些实施方式的方法。尽管下面公开了“干”方法或过程，但应当理解，本文也考虑了用本领域也已知的“湿”和其它过程形成本公开的复合泡沫制品10。
在一个实施方式中，方法包括以下步骤：
将柸料定位在加热设备中，柸料包含：
聚氨酯泡沫芯12(如上所述)，其呈现第一表面14和第二表面16，第二表面16与第一表面14反向，聚氨酯泡沫芯12具有：约2至约5、或约3至约5mm的压缩前厚度；以及约45至约80kg/m3的密度；
第一表皮18(如上所述)，其设置在第一表面14上；以及
第二表皮20(如上所述)，设置在第二表面16上；
在聚合粘合剂的熔点以上的温度下加热层压的柸料。以使聚合物熔化并且使复合泡沫制品10的层彼此粘附；以及
压缩层压的柸料，以形成复合泡沫制品10，当根据SAE J949在环境温度(约23℃)测试时，在压缩后厚度大于约2mm处，复合泡沫制品10的强度为大于17N。
在典型实施方式中，将柸料定位在加热设备中的步骤被进一步描述为在约150至约250或约170至约230℃的温度下层压柸料。在典型实施方式中，层压的步骤可被描述为包括对柸料进行表面加热(传导加热)的子步骤。在一些实施方式中，将柸料定位在加热设备中的步骤可描述为层压车顶内衬基板。
在典型实施方式中，方法还包括将层压的柸料模塑成预定形状(热成型)的步骤。典型地，加热层压的柸料和模塑层压的柸料的步骤依次进行。
在典型实施方式中，然后将层压的柸料在烤箱中经受至少约150℃的温度，然后将其转移至成型工具，在环境温度(约23℃)下持续一段时间，足以使层形成一定形状，例如，如在成型工具中限定的具有一定轮廓的车顶内衬外壳形状。在该模塑或热成型步骤中，可引入成品外层(例如，饰面材料(表面材料，facing materials)，如预粘合到柔性泡沫或非织造粗布的薄层的针织织物)。在车顶内衬的实例中，成品外层(车顶内衬覆盖料)成为具有一定轮廓的车顶内衬外壳的“A”表面，其中层压的柸料充当具有一定轮廓的结构芯(例如，车顶内衬基板)。在一些实施方式中，加热层压的柸料、压缩层压的柸料、和模塑层压的柸料的步骤可被描述为模塑车顶内衬。
在很多实施方式中，热成型操作中的加热步骤在至少约120、约120至约250、或约150至约220℃的温度下进行。在各种非限制性实施方式中，所有值与值的范围(包括上述值的值及上述值之间的值)在此明确考虑用于本文。
本文描述的很多方法步骤包括在美国专利申请公开号2008/0311336，其全部内容并入本文。
现在参考图2，示例了可作为车顶内衬基板利用的复合泡沫制品10的一个实施方式的分解横截面图。聚氨酯泡沫芯12包括半刚性聚氨酯泡沫，并且呈现第一表面14和第二表面16，第二表面16与第一表面14反向。第一表皮18被设置在第一表面14上，而第二表皮20被设置在第二表面16上。第一表皮18和第二表皮20包括多个玻璃纤维和聚合(例如，聚丙烯)粘合剂。本领域技术人员理解，作为层压过程的结果，图1中和本文其它地方描述的复合泡沫制品10的实施方式的层掺杂在一起，使得作为熔化复合泡沫制品10中的聚合材料和随后层的层压和模塑的结果可在层之间存在渐进界面。进一步，图2的实施方式包括三个附加聚合层24、24’、和24”。在一些实施方式中，附加聚合层24、24’可包括高密度聚乙烯，而24”可包括聚对苯二甲酸乙二酯粗布。当然，图2不包括车顶内衬覆盖料织物/柔性泡沫或非织造饰面材料，这些将典型地在热成型步骤中应用于该复合泡沫制品10以生产汽车车顶内衬。
现在参考图11，示例了可作为车顶内衬基板利用的复合泡沫制品110的另一实施方式的分解横截面图。聚氨酯泡沫芯112包括半刚性聚氨酯泡沫，并且呈现第一表面114和第二表面116，第二表面116与第一表面114反向。第一表皮118被设置在第一表面114上，而第二表皮120被设置在第二表面116上。第一表皮118和第二表皮120包括多种玻璃纤维和聚丙烯聚合粘合剂。本领域技术人员理解，作为层压过程的结果，图11中和本文其它地方描述的复合泡沫制品110的实施方式的层掺杂在一起，使得作为熔化复合泡沫制品110中的聚合物材料和随后的层的层压和模塑的结果，可在层之间存在渐进界面。
进一步，图11的实施方式包括三个附加聚合层124、124’、和124”。与包括包含高密度聚乙烯的附加层24、24’的图2的实例相反，图11包括包含EAA共聚物的附加层124、124’。在一些实施方式中，像在图2中，图11的附加层124”可包括聚对苯二甲酸乙二酯粗布。当然，图11不包括车顶内衬覆盖料织物/柔性泡沫或非织造饰面材料，这些材料将典型地在热成型步骤中应用于该复合泡沫制品110以生产汽车车顶内衬。
然而，现在参考图12，复合泡沫制品210可被用作车顶内衬覆盖料。在一些这样的实施方式中，车顶内衬覆盖料包含EAA共聚物。复合泡沫制品210包括聚氨酯泡沫芯212，聚氨酯泡沫芯212呈现第一表面214和第二表面216，第二表面216与第一表面214反向。进一步，包含EAA共聚物的至少一个附加层224被设置在所述第一表面214上，并且非织造、织造、皮革、或乙烯树脂(vinyl)层226被设置在所述第二表面216上。任选地，例如，包含EAA共聚物的第二附加聚合层可包括在聚氨酯泡沫芯212和非织造、织造、皮革、或乙烯树脂覆盖层226之间，覆盖层226被设置在所述第二表面216上。
现在参考图12，图12提供了可作为车顶内衬覆盖料利用的复合泡沫制品210的一个实施方式的展开横截面图。在图12的实施方式中，复合泡沫制品210(例如，车顶内衬覆盖料)包括包含柔性和/或粘弹性聚氨酯泡沫的聚氨酯泡沫芯212，并且呈现第一表面214和第二表面216，第二表面216与第一表面214反向。包含EAA共聚物的附加层224被设置在第一表面214上，并且覆盖层226(非织造、织造、皮革、或乙烯树脂)被设置在第二表面216上。
现在参考图13，示例了可作为车顶内衬基板利用的复合泡沫制品310的另一实施方式的分解横截面图。图13的复合泡沫制品310包括聚氨酯泡沫芯312、在其上包含纤维玻璃和聚丙烯的第一和第二表皮318、318’、以及两个附加层324A、324A’，所述附加层324A、324A’包括包含EAA共聚物膜的第一和第二附加层，所述附加层324A、324A’设置在第一和第二表皮318、318’和聚氨酯泡沫芯312的表面314、316之间。包含聚丙烯的另外两个附加层324B、324B’与背衬粗布(例如，包含PET)350一起被包括。应当理解，聚氨酯泡沫芯312、第一和第二表皮318、318’和附加层324A、324A’、324B、和324B’可包括以上关于上述聚氨酯泡沫芯312、表皮318、318’、和附加层324A、324A’、324B、324B’描述的各种材料，并且考虑所有此类实施方式。
在一些实施方式中，本文描述的并包括包含EAA共聚物的附加聚合层的复合泡沫制品10被用于/是座椅部件(例如，座椅衬面)。再次参考图12，示例的复合泡沫制品210还可用作座位(seating)部件。为此目的，复合泡沫制品210可以是座位部件并可被称为座位部件。如本公开全文使用的，属于“座椅部件”与垫子(即，占有者/乘客坐在座椅上的部分)、靠板或靠背(back rest)(即，支撑占有者/乘客的背部的座椅的部分)、和座椅侧垫(即，垫子、靠板或靠背的延伸，其横向支撑占有者/乘客)中的一个、一些或全部连接使用。
例如，在一些实施方式中，复合泡沫制品210是座椅部件，其包括：
聚氨酯泡沫芯212，其呈现第一表面214和第二表面216，第二表面216与第一表面214反向；
包含EAA共聚物的附加聚合层224，其设置在第一表面214上，
包含EAA共聚物(未示出)的附加聚合层，其可任选地设置在第一表面214上；以及
覆盖层226(非织造、织造、皮革、或乙烯树脂)，其设置在第二表面216上。
在很多底座实施方式中，复合泡沫制品10包括柔性和/或粘弹性聚氨酯泡沫。
进一步，在此类底座实施方式中，非织造、织造、皮革、或乙烯树脂层24可被火焰粘合(flame bonded)至第二表面16。在这样的实施方式中，复合泡沫制品10的火焰粘合后的总厚度为约1至约10mm。
应当理解，上述复合泡沫制品10可以任意组合使用。本文考虑的各种复合泡沫制品10包括层压件，用于作为包含所描述的层的各种组合的车顶内衬、车厢地板、座椅部件、遮阳帘、遮阳板、后座椅靠背板、和后窗台来使用。
以下实例旨在说明本公开，并且不应以任何方式理解为限制本公开的范围。
实施例
在下面汽车车顶内衬应用中描述复合泡沫制品的实施例。通常，实施例显示本公开的复合泡沫制品的各种实施方式如何在不同压缩和厚度下提供出色的强度和硬度。
实施例1和2
在图2和下表1中描述了实施例1的车顶内衬基板的复合泡沫制品。下表1还描述了比较实施例1的车顶内衬基板的复合泡沫制品。两种示例性复合泡沫制品包括聚氨酯泡沫芯，其中第一和第二表皮在其上包含纤维玻璃和聚丙烯。在表1中，实施例1和比较实施例1被轻微压缩(at 4mm)、和更显著压缩(4mm至2mm)，这经常发生在成形的车顶内衬的多个区域中。
表1
Figure BDA0003066181320000131
根据SAE J949在约2mm和约4mm的厚度处，对实施例1和比较实施例1的强度和硬度进行测试，并且在室温(约23℃)下和高温(约80℃)下的结果示于图3-6中。
现在参考图3-6，实施例1包括密度为69kg/m3的聚氨酯泡沫芯并且包括每单位面积的总重量为875g/m2的第一和第二表皮，相对于比较实施例1展示出显著更高的强度和硬度，比较实施例1具有密度为kg/m3的聚氨酯泡沫芯并且包括每单位面积的总重量为914g/m2的第一和第二表皮。由此，具有初始密度为69kg/m3的聚氨酯泡沫芯并且每单位面积的重量为875g/m2的实施例1在4mm和2mm处以及在室温(约23℃)下和在高温(约80℃)下均展示相对于比较实施例1更好的强度和硬度。
进一步，实施例1展示结实的触感(较不柔软)，而比较实施例1展示较软的触感，例如，当施加拇指压力时。
实施例1具有柔性聚氨酯泡沫芯，其密度为69kg/m3，在23℃下CFD(在10％挠度下)为80psi，并且在成型温度(200℃)下伸长率为30％。令人惊讶的是，实施例1的聚氨酯泡沫芯赋予图3-6中所示的出色的强度和挠性特征。实施例1和比较实施例1的泡沫芯之间的差异示于下表2中。
表2
Figure BDA0003066181320000141
下表3提供实施例1和2以及比较实施例1-4的描述。
表3
Figure BDA0003066181320000151
现在参考图7-10，将实施例1和2的强度和硬度与各种比较基板进行比较以说明它们的惊人的强性能特征。
鉴于图7-10，描述了实施例的高密度高模量聚氨酯泡沫芯(69kg/m3，在23℃下80psi CFD(在10％挠度下)，并且在200℃的成型温度下伸长率为30％)和表皮(泡沫重量％增加至100PBW基板的30重量％)，证明了在较低每单位面积重量下强度和硬度性能的巨大提高。
实施例3-6
实施例3-6和比较实施例5-8的车顶内衬基板的复合泡沫制品描述于下表4中。实施例3-6包括聚氨酯泡沫芯(其中第一和第二表皮包含在其上的纤维玻璃和聚丙烯)以及两个附加层，所述两个附加层包含EAA共聚物膜(13gsm)，所述两个附加层被设置在第一和第二表皮与聚氨酯泡沫芯的表面之间。包含聚丙烯的另外两个附加层与背衬粗布一起被包括。与实施例3-6相反，比较实施例5-8利用两个附加层，该两个附加层包含HDPE膜(28gsm)，该两个附加层被设置在第一和第二表皮和聚氨酯泡沫芯的表面之间，除了EAA共聚物层被替换，比较实施例5-8的层的构型与实施例3-6相同。对于实施例3-6和比较实施例5-8的车顶内衬基板构型的分解视图，请进一步参考图13。
表4
Figure BDA0003066181320000161
现在参考表4，实施例3-6包括聚氨酯泡沫芯(其中第一和第二表皮包含在其上的纤维玻璃和聚丙烯)以及两个附加层，所述两个附加层包含EAA共聚物膜(13gsm)，实施例3-6相对于比较实施例5-8展示出色的气体流动，比较实施例5-8利用包含HDPE膜(28gsm)的两个附加层。
现在参考图14，改善的气体流动有助于在较高频率下改善吸声。图14是实施例5和比较实施例7的吸声的图解分析。实施例5展示在较高频率下改善的吸声，这在汽车应用中是期望的。
现在参考图15和16，包含EAA共聚物膜(13gsm)的两个附加层令人惊讶地在实施例的聚氨酯泡沫芯与第一和第二表皮之间提供结实的粘合。事实上，实施例的包含EAA共聚物的两个附加层以每平方米13克利用，而包含HDPE的比较实施例的两个附加层以每平方米28克使用，并且EAA共聚物仍然胜过HDPE。换句话说，包含EAA共聚物的实施例通常胜过比较实施例——包含超过两倍的HDPE。图15是将实施例3、4、和5与比较实施例5、6、和7的第一表皮(在基板的“A面”上)与聚氨酯泡沫芯之间的撕裂强度进行比较的图解分析。图16是将实施例3、4、和5与比较实施例5、6、和7的第二表皮(在基板的“C面”上)与聚氨酯泡沫芯之间的撕裂强度进行比较的图解分析。“非烤制”名称涉及层压后的基板板状况(substrate boardcondition)。“烤制(toasted)”名称涉及将该板加热至大约200℃，然后在平板工具(flatplaque tool)中将其轻微压缩以模拟热成型操作。
实施例3-6和比较实施例5-8通过三点弯曲测试来测试，三点弯曲测试提供弯曲(Emod)数据中的强度(Fmax)、硬度、和弹性模量。现在参考图18，实施例3-6展示与相应比较实施例5-8相同的强度，如果不是则展示比相应比较实施例5-8更好的强度。现在参考图18，实施例3-6展示与相应比较实施例5-8相同的硬度，如果不是则展示比相应比较实施例5-8更好的硬度。
利用垂度测试以确定高温下的强度。为了测试垂度，每个相应实施例/比较实施例的2”×10”样品在样品的一端处保持静止，并且将22g砝码(weight)放置在样品的另一端上。将样品放置在80℃的烤箱中，并测量其初始高度。每小时温度增加10℃持续5小时，并且记录高度或“垂度”的下降。现在参考图19，实施例3和4展示与相应比较实施例5和6相同的垂度，如果不是则展示比相应比较实施例5和6更好的垂度。
总之，实施例3-6展示出与相应比较实施例相比显著改善的气体流动和撕裂强度。值得注意的是，对于非烤制板(即，层压条件)，撕裂强度显著改善。这在层压中提供更宽的制程窗口(process window)以满足指定非烤制板撕裂强度要求。
从气体流动角度来看，包含EAA共聚物的附加层提供出色的声学性能和部分剥离(peel in part)，因为其熔化以形成对聚氨酯具有出色的附着力的多孔层。包含EAA共聚物的附加层(例如，厚度为约5至约30、10至约20、或约13gsm(g/m2))具有类似于聚氨酯泡沫芯层的孔或开口。在图20中，实施例4中包含EAA共聚物的附加层的放大图像显示了覆盖泡沫芯层的部分表面，而不覆盖泡沫芯层的表面和孔的各个部分。以洒点法(stippling)示出被包含EAA的附加层覆盖的表面的区域。图20示例在添加包含EAA共聚物的附加层之后，本公开的复合泡沫制品如何能够维持高气体流动，因为聚氨酯泡沫芯的孔隙率不受EAA共聚物影响。有利地，层对聚氨酯泡沫芯的附着力也随着包含EAA的附加层的使用而增加。
相对于相应比较实施例，实施例3-6也展示了同等的强度、硬度、和垂度。进一步，实施例3-6与比较实施例相比产生改善性能，同时减少了每平方米的重量。
应当理解，所附权利要求不限于表示在详细描述中描述的任何具体的化合物、组合物、或方法，其可以在落入所附权利要求内的具体实施方式之间变化。关于依赖本文用于描述各种实施方式的具体特征或方面的任何马库什基团，应当理解不同、特殊、和/或以外结果可从独立于所有其它马库什成员的相应马库什基团的每个成员获得。马库什基团的每个成员可被单独依赖和或组合依赖，并在所附权利要求的范围内为具体实施方式提供足够的支持。
还应理解，依赖于独立地且共同地描述本公开的各种实施方式的任何范围和子范围落入所附权利要求的范围内，并且被理解为描述和考虑其中包括整数和/或分数值的所有范围，即使本文没有明确写明这些值。本领域技术人员容易认识到，列举的范围和子范围足以描述并且能够使本公开的各种实施方式成为可能，并且这些范围和子范围可被进一步勾画成相关的二分之一、三分之一、四分之一、五分之一、等等。仅作为一个实例，“0.1至0.9的”范围可被进一步勾画成下三分之一，即，0.1至0.3，中三分之一，即，0.4至0.6，和上三分之一，即，0.7至0.9，其单独地和共同地在所附权利要求的范围内，并且可被单独地和/或共同地依赖，并且为所附权利要求的范围内的具体实施方式提供足够的支持。另外，关于限定或修饰范围的语言，如“至少”、“大于”、“小于”、“不多于”等，应理解这样的语言包括子范围和/或上限或下限。作为另一实例，“至少10”的范围固有地包括至少10至35的子范围、至少10至25的子范围、25至35的子范围等，并且每个子范围可被单独地和/或共同地依赖，并且为所附权利要求的范围内的具体实施方式提供足够的支持。最后，所公开范围内的单个数字可被依赖，并且为所附权利要求的范围内的具体实施方式提供足够的支持。例如，1至9的”范围包括各种单个整数(如3)，以及包括小数点(或分数)的单个数字(如4.1)，其可被依赖，并且为所附权利要求的范围内的具体实施方式提供足够的支持。
本公开已经以说明性方式描述，并且应当理解已被使用的术语旨在具有描述而不是限制的词语的性质。显然，根据上述教导，本公开的很多修改和变化是可能的。因此，应当理解，在所附权利要求的范围内，本公开可被以不同于具体描述的方式来实践。

Claims (20)

1.一种复合泡沫制品，包括：
聚氨酯泡沫芯，所述聚氨酯泡沫芯呈现第一表面和第二表面，所述第二表面与所述第一表面反向，所述聚氨酯泡沫芯具有约45至约80kg/m3的密度；
第一表皮，所述第一表皮设置在所述第一表面上，包含多个纤维和聚合粘合剂；
第二表皮，所述第二表皮设置在所述第二表面上，包含多个纤维和聚合粘合剂；以及
其中聚氨酯泡沫芯、所述第一表皮、所述第二表皮具有约2至约5mm的压缩前厚度，并且被压缩以以形成复合泡沫制品，当根据SAE J949在约23℃下测试时，在压缩后厚度大于约2mm处，所述复合泡沫制品的强度为大于17N。
2.权利要求1所述的复合泡沫制品，所述复合泡沫制品的每单位面积的重量为约500至约1,000g/m2。
3.权利要求1所述的复合泡沫制品，所述复合泡沫制品的每单位面积的重量为约750至约1,000g/m2。
4.权利要求2所述的复合泡沫制品，其中所述第一表皮和第二表皮累积贡献了所述复合泡沫制品的每单位面积的总重量的约25至约60％。
5.任一前述权利要求所述的复合泡沫制品，其中所述聚合粘合剂包括选自聚乙烯和聚丙烯的聚合物。
6.任一前述权利要求所述的复合泡沫制品，其中所述纤维包括选自聚合物、陶瓷、玻璃、金属、矿物、和碳的材料。
7.任一前述权利要求所述的复合泡沫制品，其中所述纤维包括选自E-玻璃(氧化铝-钙-硼硅酸盐)、S2玻璃(镁-铝-硅酸盐)、C玻璃(硼硅酸钙)、和R玻璃(钙-铝-硅酸盐)、二氧化硅、和石英的玻璃。
8.任一前述权利要求所述的复合泡沫制品，除了所述聚合粘合剂之外，进一步包括聚烯烃膜或粉末。
9.任一前述权利要求所述的复合泡沫制品，其中当根据ASTM D3574-D测量时，所述聚氨酯泡沫芯在10％挠度下的压缩力挠度为约10至约110psi。
10.复合泡沫制品，当根据ASTM 790-98在约23℃下测试时，当在约1.5mm至约5mm的压缩后厚度处测试时，所述复合泡沫制品的硬度大于约3N/mm。
11.权利要求1所述的复合泡沫制品，进一步包括捕获层，所述捕获层包括碳颗粒，所述碳颗粒的表面积大于约300m2/g。
12.权利要求10所述的复合泡沫制品，其中所述碳颗粒以约2至约50g/m2的量存在。
13.权利要求10或11所述的复合泡沫制品，其中所述碳颗粒具有约5至约1,000μm的粒度和/或约500至约3000m2/g的表面积。
14.一种车辆车顶内衬、遮阳帘、遮阳板、后窗台、座椅靠背、或车厢地板，其包含任一前述权利要求所述的复合泡沫制品。
15.制备复合泡沫制品的方法，所述方法包括以下步骤：
将柸料定位在加热设备中，所述柸料包括：
聚氨酯泡沫芯，所述聚氨酯泡沫芯呈现第一表面和第二表面，所述第二表面与所述第一表面反向，所述聚氨酯泡沫芯具有约3至约5mm的压缩前厚度和约45至约80kg/m3的密度；
第一表皮，所述第一表皮设置在所述第一表面上，所述第一表面包含多个纤维和聚合粘合剂；和
第二表皮，所述第二表皮设置在所述第二表面上，所述第二表面包含多个纤维和聚合粘合剂；
在所述聚合粘合剂的熔点以上的温度下加热所述柸料，以使所述聚合物熔化，并且使所述复合泡沫制品的层彼此粘附；以及
压缩所述柸料以形成所述复合泡沫制品，当根据SAE J949测试时，在压缩后厚度大于约1.5mm处，所述复合泡沫制品的强度大于22N。
16.权利要求15所述的方法，其中压缩的步骤进一步被限定为将所述柸料模塑成预定形状。
17.权利要求15或16所述的方法，其中将柸料定位在加热设备中的步骤进一步被描述为在约150至约250℃的温度下层压柸料。
18.权利要求15-17中任一项所述的方法，其中所述复合泡沫制品的每单位面积的压缩后重量为约500至约1,000g/m2。
19.权利要求15-18中任一项所述的方法，其中所述第一表皮和第二表皮累积贡献了所述复合泡沫制品的每单位面积的总重量的约25至约60％。
20.权利要求15-19中任一项所述的方法，其中至少一个增强层包括多个纤维子层。
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Application publication date: 20210625